orbital stretch wrapping machine

Understanding Orbital Stretch Wrapping Machines for Aluminum Profile Bundles

Orbital stretch wrappers, also commonly referred to as horizontal stretch wrappers, represent a specialized category of packaging machinery designed primarily for securing long, bulky, or irregularly shaped products. This guide focuses on their application in packaging aluminum profiles and bundles, a critical process for protecting materials during handling, storage, and transit.

1. Operational Demonstration

The following video illustrates a typical orbital stretch wrapping machine processing aluminum bundles formed by a preceding bundle maker system. Observe how the wrapping ring dispenses the film around the stationary bundle.

2. Core Functionality and Working Principle

Unlike traditional turntable stretch wrappers where the load rotates, an orbital wrapper keeps the product stationary (usually moving horizontally on conveyors) while a wrapping ring holding the stretch film roll revolves around the product.

• Product Infeed: Bundles of aluminum profiles enter the machine, typically via powered roller or belt conveyors.
• Wrapping Cycle: As the bundle passes through the wrapping ring's opening, the ring rotates, dispensing stretch film and wrapping it around the bundle's perimeter.
• Film Application: The film carriage system on the ring precisely controls film tension and pre-stretch (if equipped), ensuring a tight, secure wrap without damaging the profiles.
• Customizable Programs: Advanced systems allow operators to define specific wrapping programs. This can include:
  • Varying the number of wraps at the leading and trailing ends for extra reinforcement.
  • Adjusting wrap overlap percentage.
  • Setting different tension levels for different parts of the bundle.
  • Applying over-wrapping at specific points requiring additional protection.
• Film Cut and Clamp: Upon cycle completion, an automated mechanism clamps the film, cuts it, and often secures the tail to the bundle, preparing the machine for the next cycle.
• Product Outfeed: The fully wrapped bundle exits the machine on an outfeed conveyor.
  

  

  3. Key Components and Features

Understanding the main parts of an orbital wrapper helps in appreciating its operation and capabilities:

• Infeed and Outfeed Conveyors: Transport the bundles into and out of the wrapping zone. Often feature guides or pneumatic clamps to stabilize the load.
• Wrapping Ring Assembly: The rotating ring that carries the film dispensing system. Ring diameter dictates the maximum bundle cross-section.
• Film Carriage System: Holds the stretch film roll. May include:
  • Mechanical or Powered Pre-Stretch: Stretches the film before application (up to 250-300% typically), maximizing film yield and improving load containment.
  • Tension Control: Ensures consistent film tension during wrapping.
• Automatic Cut & Clamp Unit: Automates the film cutting and securing process for continuous operation.
• Control System (PLC): The machine's brain, allowing users to set parameters, store wrapping programs, and manage operation via an HMI (Human-Machine Interface).
• Safety Features: Emergency stops, safety guarding, light curtains to protect operators.

4. Typical Technical Parameters (Example Range)

Specifications vary significantly based on machine model and application requirements. Typical ranges include:

• Ring Rotation Speed: 30 - 90 RPM (Revolutions Per Minute)
• Conveyor Speed: 5 - 15 meters/minute (Adjustable)
• Maximum Bundle Dimensions (L x W x H): Dependent on ring size and machine configuration (e.g., L: 6000mm, W: 500mm, H: 300mm)
• Stretch Film Roll Width: 100mm - 500mm
• Stretch Film Roll Outer Diameter (OD): Up to 250mm
• Stretch Film Roll Core ID: Typically 76mm (3 inches)
• Power Requirements: e.g., 480V, 3-Phase, 60Hz (Varies by region and machine size)
• Compressed Air: Required for pneumatic components (e.g., clamps, cutters), typically 6-8 Bar.

5. Primary Applications & Industries

While highly effective for aluminum profiles and extrusions, orbital wrappers are also used for:

• Pipes, tubes, and conduits
• Timber and lumber bundles
• Doors and windows
• Textile rolls
• Other long or awkwardly shaped products

The primary benefit lies in securely unitizing and protecting items that are difficult or impossible to wrap on standard turntable machines.

6. Operational Considerations and Experience Sharing

Effective operation involves more than just pressing 'start'. Consider these points:

• Bundle Preparation: Ensure bundles are consistently formed and stable before entering the wrapper. Loose profiles can cause wrapping issues or damage.

• Film Selection: Use high-quality stretch film appropriate for the load weight, profile sharpness, and required containment force. Consider film thickness (gauge) and pre-stretch compatibility.

• Tension Adjustment: Proper tension is crucial. Too loose, and the load isn't secure. Too tight, and delicate profiles could be damaged. Run tests to find the optimal setting.

• Program Optimization: Leverage programmable controls to apply film precisely where needed, minimizing waste while maximizing protection (e.g., extra wraps on ends).

• Routine Maintenance: Regularly inspect and clean film rollers, cutters, clamps, and sensors. Follow the manufacturer's lubrication schedule for bearings and moving parts. Check pneumatic pressures and electrical connections.

• Operator Training: Ensure operators understand machine functions, safety procedures, film loading, and basic troubleshooting.
  

  7. Benefits of Orbital Stretch Wrapping for Aluminum

• Enhanced Product Protection: Provides a tight, conforming wrap that shields aluminum surfaces from scratches, dust, moisture, and shifting during transit.

• Improved Load Stability: Securely unitizes bundles, preventing individual profiles from separating or moving.

• Increased Throughput: Automated operation significantly speeds up the packaging process compared to manual methods.

• Reduced Labor Costs: Minimizes manual handling and wrapping requirements.

• Material Savings: Systems with powered pre-stretch can significantly reduce film consumption per bundle compared to manual or no-pre-stretch wrapping.

• Versatility: Can handle various bundle lengths and profiles with appropriate machine configuration and programming.

8. Conclusion

The orbital stretch wrapping machine is an indispensable tool in the aluminum extrusion industry and other sectors dealing with long products. Its ability to provide consistent, secure, and protective wrapping automatically delivers significant operational efficiencies and product integrity benefits. By understanding its working principles, key components, and operational best practices, facilities can fully leverage this technology for optimized packaging outcomes.

For further details on specific solutions tailored to aluminum packaging needs:
https://www.fhopepack.com/Aluminum/

Disclaimer: Technical specifications are examples and vary by manufacturer and model. Always consult manufacturer documentation for specific machine details.